Coating composition and resin molded article coated thereby

ABSTRACT

A coating composition for forming an undercoat layer, which contains a copolymer obtained from the following monomer compounds (i), (ii) and (iii), 
     (i) an acrylic or methacrylic compound, 
     (ii) an alkoxysilyl group-containing acrylic or methacrylic compound and 
     (iii) an acrylic or methacrylic compound having ultraviolet light absorbability such as benzophenone-substituted acrylic monomer or triazole-substituted acrylic monomer, 
     and a coated resin molded article coated with an undercoat layer of the above coating composition, and with an overcoat layer of an organopolysiloxane-containing coating composition.

This is a division of application Ser. No. 07/749,749, filed Aug. 26,1991, now U.S. Pat. No. 5,191,045.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a coating composition excellent inweatherability and abrasion resistance, and a resin molded articlecoated with the composition.

2. Prior Art of the Invention

In general, polycarbonate resins are widely used as a transparent resinmaterial due to their excellent impact resistance and transparency.However, polycarbonate resins have defects in that they are poor inabrasion resistance and solvent resistance and that the surface of amolded article produced therefrom is easily scratched and easilycorroded with an organic solvent. In order to overcome these defects,there have been proposed a variety of methods in which such a moldedarticle is coated with a thermosetting resin.

In order to improve the properties, abrasion resistance, etc., oftransparent resin articles such as molded articles produced from theabove polycarbonate resins, well known are resin articles which arecoated, as an undercoat layer, with a coating composition comprising anacrylic polymer and further coated, as an overcoat layer, with a coatingcomposition comprising either a silicon compound or a partial hydrolysisproduct of a silicon compound and a colloidal metal oxide composedmainly of colloidal silica (TOKKAI 59-109528(1984), etc.). And, theundercoat layer of an acrylic polymer often contains an ultravioletlight absorber in order to prevent crack and a decrease in adhesion toanother coating layer, which occur due to photo-oxidative deteriorationcaused on an article surface by ultraviolet light.

However, such resin articles sometimes turn yellow, suffer cracks orhave a coating layer peeled off under the influence of ultravioletlight, water, heat, etc., when used for a long period of time. Thesephenomena are caused for the following reason. When such resin articlesare used for a long period of time, the ultraviolet light absorbermigrates onto the coating layer surface and dissipates, i.e. it wouldnot remain on the resin article surface, and the ultraviolet lightabsorption effect is gradually decreased.

Further, when there is employed a method such as an immersion method, aflow-coat method, or the like, in which an overcoating liquid forcoating an undercoated resin article with an overcoat layer isrepeatedly used, the ultraviolet light absorber contained in theundercoat layer is eluted into the overcoating liquid when brought intocontact with the overcoating liquid, and the concentration of theultraviolet light absorber in the overcoating liquid graduallyincreases. As a result, the resultant overcoating liquid showsdefectiveness in hardness, a decrease in adhesion properties, etc., andthe pot life of such an overcoating liquid decreases.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a coatingcomposition for use on a weathering-resistant and abrasion-resistantresin molded article as an undercoat layer of a polymer havingultraviolet light absorbability, which composition prevents occurrenceof crack and yellowing and a decrease in adhesion properties when themolded article is used for a long priod of time, and a resin moldedarticle coated with an undercoat layer of the composition.

DETAILED DESCRIPTION OF THE INVENTION

The above object of the present invention is achieved by the followingconstitution. That is, according to the present invention, there isprovided a coating composition for forming an undercoat layer, whichcontains a copolymer obtained from the following monomer compounds (i),(ii) and (iii),

(i) an acrylic or methacrylic compound containing at least one of thecompounds of the formulae (I) and (II), ##STR1## wherein R¹ is hydrogenor a methyl group and R² is an alkyl group, ##STR2## wherein R¹ ishydrogen or a methyl group, R³ is an alkylene group, and X is a hydroxylgroup, a carboxyl group, an amine group, an epoxy group, an amido groupor Si(OR⁴)₃ in which R⁴ is an alkyl group,

(ii) an alkoxysilyl group-containing acrylic or methacrylic compound ofthe formula (III), ##STR3## wherein R¹ is hydrogen or a methyl group, R⁵is a hydrocarbon group having 1 to 6 carbon atoms, R⁶ is a hydrocarbongroup having 1 to 5 carbon atoms, an alkoxyalkyl group or an acyl grouphaving 1 to 4 carbon atoms, and d is 0, 1 or 2, and

(iii) an acrylic or methacrylic compound having ultraviolet lightabsorbability.

According to the present invention, there is also provided a coatedresin molded article obtained by coating a resin molded article with anundercoat layer of the above composition of the present invention andthen with an overcoat layer of a coating composition containingorganopolysiloxane.

In addition, the above (iii) acrylic or methacrylic compound havingultraviolet light absorbability, one component for forming an undercoatlayer, is selected, for example, from a benzophenone-substituted acrylicmonomer of the formula (IV), ##STR4## wherein R¹ is hydrogen or a methylgroup, R⁷ is an alkylene group --(CH₂)_(n) -- in which n is 1 to 5 or ahydroxyalkylene group, Z is hydrogen, a hydroxyl group or a carboxylgroup, X is hydrogen or an alkoxy group OR⁸ in which R⁸ is an alkylgroup of C_(n) H_(2n+1) in which n is 1 to 20, and Y is hydrogen,chlorine or a sulfonic acid group, and a triazole-substituted acrylicmonomer of the formula (V), ##STR5## wherein R¹ is hydrogen or a methylgroup, R⁷ is an alkylene group --(CH₂)_(n) -- in which n is 1 to 5 or ahydroxyalkylene group, R⁸ is an alkyl group C_(n) H_(2n+1) in which n is1 to 20, and X is hydrogen or chlorine. These may be used alone or incombination.

In the coating composition for forming an undercoat layer, the copolymeris obtained from 5 to 85% by weight, preferably 30 to 70% by weight ofthe compound (i), 5 to 45% by weight, preferably 15 to 30% by weight ofthe compound (ii) and 10 to 50% by weight, preferably 15 to 40% byweight of the compound (iii).

When the amount of the compound (i) is less than 5% by weight, theadhesion to a molded article is poor, and when it exceeds 85% by weight,the adhesion to an overcoat layer is liable to decrease. When the amountof the compound (ii) is less than 5% by weight, the adhesion to anovercoat layer is poor, and when it is more than 45% by weight, theadhesion to a molded article is liable to decrease. When the amount ofthe compound (iii) is less than 10% by weight, no efficient effect onresistance to ultraviolet light can be expected, and when it is morethan 50% by weight, the adhesion to a molded article is poor.

The compound of the formula (I) is selected, for example, from methyl(meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, butyl(meth)acrylate, etc.

The compound of the formula (II) is selected, for example, fromhydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate,hydroxymethylaminomethyl (meth)acrylate, dihydroxymethylaminomethyl(meth)acrylate, glycidoxypropyl (meth)acrylate, dimethylaminoethyl(meth)acrylate, diethylaminoethyl (meth)acrylate, dibutylaminoethyl(meth)acrylate, dimethylaminopropyl (meth)acrylate, etc.

The compound of the formula (III) is selected, for example, fromγ-(meth)acryloxypropyltrimethoxysilane,γ-(meth)acryloxypropyltriethoxysilane,γ-(meth)acryloxypropylmethyldimethoxysilane,γ-(meth)acryloxypropylmethyldiethoxysilane,γ-(meth)acryloxypropyldimethylmethoxysilane,τ-(meth)acryloxypropyldimethylethoxysilane, etc.

The compound of the formula (IV) is selected, for example, from2-hydroxy-4-(2-hydroxy-3-methacryloxy)propoxybenzophenone,2-hydroxy-2'-carboxy-4(2-hydroxy-3-methacryloxy)propoxybenzophenone,2,2'-dihydroxy-4-(2-hydroxy-3-methacryloxy)propoxybenzophenone,2-hydroxy-4'-methoxy-4-(2-hydroxy-3-methacryloxy)propoxybenzophenone,2-hydroxy-5-sulfonic-4-(2-hydroxy-3-methacryloxy)propoxybenzophenone,2,2'-dihydroxy-4'-methoxy-4-(2-hydroxy-3-methacryloxy)propoxybenzophenone,etc.

The compound of the formula (V) is selected, for example, from2-[2'-hydroxy-5'-(2-hydroxy-3-methacryloxy)propoxyphenyl]benzotriazole,2-[2'-hydroxy-3'-tertbutyl-5'-(2-hydroxy-3-butyl-5'-(2-hydroxy-3-methacryloxy)propoxyphenyl]benzotriazole,2-[2'-hydroxy-3'-tert-amyl-5'-(2-hydroxy-3-methacryloxy)propoxyphenyl]benzotriazole,2-[2'-hydroxy-3'-tertbutyl-5'-(2-hydroxy-3-methacryloxy)propoxyphenyl]-5-chlorobenzotriazole,2-[2'-hydroxy-3'-di(1,1-dimethylbenzyl)-5'-(2-hydroxy-3-methacryloxy)propoxyphenyl]benzotriazole,etc.

The undercoat layer is generally obtained by drying a coating liquid ofthe composition under heat at a temperature between 80° C. and 130° C.for 15 minutes to 3 hours.

The thickness of the undercoat is preferably 0.2 to 15 μm, morepreferably 0.5 to 10 μm. When this thickness is less than 0.2 μm, theweatherability is hardly improved. When it exceeds 15 μm, a crack easilyoccurs in a weathering test.

An organopolysiloxane-containing coating composition is suitably usableto form an overcoat layer. The organosiloxane-containing coatingcomposition refers to a silicon compound-containing coating compositionobtained by partially hydrolyzing a silanol compound of the formula(VI),

    R.sup.8 Si(OH).sub.3                                       (VI)

wherein R⁸ is an alkyl group having 1 to 3 carbon atoms, a vinyl group,a trifluoropropyl group, γ-glycidoxypropyl group, γ-aminopropyl group orγ-methacryloxypropyl group, in the presence of an aqueous or alcoholdispersion of colloidal metal oxide.

In addition to the above coating composition, a melamine-based resin andan acrylic resin may by used to form an overcoat layer. The thickness ofthe overcoat layer is preferably 1.0 to 8 μm, the most preferably 3 to 5μm. When the overcoat layer thickness is less than 1.0 μm, the abrasionresistance is hardly improved. When it exceeds 8 μm, a crack is liableto occur easily.

The overcoat layer is generally obtained by drying a coating liquid ofthe above composition under heat at a temperature between 80° C. and150° C. for 15 minutes to 5 hours. The above treatment conditions areselected depending upon the heat resistance of molded articles. Thedrying takes longer under heat at a lower temperature, and the time forthe drying is decreased under heat at a higher temperature.

Further, the coating composition of the present invention may contain anultraviolet light absorber and an antioxidant.

The coating composition of the present invention is mainly effective formolded articles of polycarbonate which is susceptible to photo-oxidativedeterioration due to ultraviolet light, and it can be also applied tomolded articles obtained, for example, from polyacryl(heat-resistantacry), polyethylene terephthalate, polystyrene, an acrylonitrile/styrenecopolymer, etc. Being excellent in transparency, the coating compositionof the present invention is particularly suitable for coating articlesof the above transparent resins.

The above coating composition for forming an undercoat layer is appliedto the surface of a resin molded article, and the resultant coatinglayer is baked at a temperature lower than the thermal deformationtemperature of the resin molded article or air-dried, whereby anundercoat layer is formed. Then, the above coating composition forforming an overcoat layer is applied onto the above undercoat layer, andcured.

EXAMPLES Example 1

(a) Preparation of a coating liquid for an undercoat layer: Components(i), (ii) and (iii) were used in such a compositional ratio that thecontent of the component (i) was 70% by weight, that of the component(ii) was 20% by weight and that of the component (iii) was 10% byweight. That is, 78.4 g of methyl methacrylate [component (i)], 22.4 gof γ-acryloxypropyltrimethoxysilane [component (ii)], 11.2 g of2-hydroxy-4-(2-hydroxy-3-methacryloxy)propoxybenzophenone [component(iii)] and 0.5 g of azobisisobutyronitrile were dissolved in 205 g ofpropylene glycol monomethyl ether, and under nitrogen atmosphere, theresultant mixture was stirred under heat at 85° C. for 4 hours tocopolymerize the above components.

The resultant copolymer had a solid content of 35% and a viscosity of1,000 cps. 100 Grams of propylene glycol monomethyl ether was added to100 g of the copolymer to prepare a coating liquid for forming anundercoat layer.

(b) Preparation of a coating composition for an overcoat layer: 207Grams of methyltrimethoxysilane and 7.0 g of acetic acid were added to68.0 g of colloidal silica in solid (aqueous dispersion having a solidcontent of 34%), and the resultant mixture was stirred for hydrolysisfor 2 hours while the temperature of the mixture was maintained at 50°C. Thereafter, 195 g of n-butanol, 195 g of isopropyl alcohol, 1.26 g ofsodium acetate and 11.0 g of acetic acid were added to prepare a coatingliquid for forming an overcoat layer.

The above coating liquid (a) for forming an undercoat layer was appliedto a preliminarily washed polycarbonate substrate, air-dried for 15minutes, and dried under heat at 125° C. in a hot-air drying furnace for20 minutes. The dried undercoat layer had a thickness of 3.7 μm. Then,the above coating liquid (b) for forming an overcoat layer was appliedto the undercoat layer surface of the polycarbonate substrate, air-driedfor 15 minutes, and dried under heat at 125° C. in a hot-air dryingfurnace for 60 minutes. The dried overcoat had a thickness of 3.8 μm.

The resultant coated polycarbonate article had a transparent coating,and showed an abrasion resistance of A, an ahdesion of 100/100 andexcellent water resistance. After it was subjected to a sunshineweatherometer test over 3,000 hours, it had an excellent appearance, anexcellent hardness and excellent adhesion properties.

Further, when about 100 polycarbonate plates coated with the sameundercoat layer as above were immersed in the same coating liquid forforming an overcoat as that used above, no decrease in adhesionproperties was observed. The pot life of the coating liquid for formingan overcoat was also sufficient. In addition, the coating on an articlewas evaluated by the following methods.

Abrasion resistance: A #0000 steel wool was rubbed against a coating toexamine ease and difficulty in forming scratch, and the results wereevaluated as follows.

A: No scratch even if a coating was rubbed forcefully.

B: Scratched to a little extent when a coating was rubbed forcefully.

C: Scratched even when a coating was rubbed lightly.

Adhesion properties: A so-called crosscut test was carried out. Acoating surface was cut 11 times lengthwise and 11 times widthwise atintervals of 1 mm each to form 100 squares, and a cellophane adhesivetape was applied to the crosscut section and peeled. The results wereshown as a number of squares which had remained unpeeled among the 100squares.

Water resistance: A coated article was allowed to stand in a warm waterhaving a temperature of 60° C. for 7 days, and the coated article wasexamined with regard to failures such as whitening, a crack, peel, etc.

Accelerated weathering test: The weatherability of a coated article wasevaluated with a sunshine carbon arc weatherometer. In addition, thistest was conducted at a black panel temperature of 63°±3° C., and at awater spraying cycle of 12 minutes/hour.

Example 2

(a) Preparation of a coating liquid for forming an undercoat layer:Components (i), (ii) and (iii) were used in such a compositional ratiothat the content of the component (i) was 60% by weight, that of thecomponent (ii) was 20% by weight and that of the component (iii) was 20%by weight. That is, 63 g of ethyl methacrylate [component (i)], 21 g ofγ-acryloxypropyltrimethoxysilane [component (ii)], 21 g of2-[2'-hydroxy-3'-tert-butyl-5'-(2-hydroxy-3-methacryloxy)propoxyphenyl]benzotriazole[component (iii)] and 0.5 g of azobisisobutyronitrile were dissolved in195 g of ethylene glycol monoethyl ether, and under nitrogen atmosphere,the resultant mixture was stirred under heat at 90° C. for 4 hours tocopolymerize the components.

The resultant copolymerization product had a solid content of 35% and aviscosity of 900 cps. 400 Grams of ethylene glycol monoethyl ether wasadded to 100 g of the copolymer to prepare a coating liquid for formingan undercoat layer.

(b) Preparation of a coating liquid for forming an overcoat layer: 80Grams of γ-glycidoxypropyltrimethoxysilane, 144 g ofmethyltrimethoxysilane, 15 g of colloidal silica in solid (aqueousdispersion having a solid content of 40%), and 170 g of a 1Nhydrochloric acid aqueous solution were mixed, and the resultant mixturewas refluxed at a temperature between 80° C. and 85° C. for 2 hours forhydrolysis. Then, 73 g of ethyl cellosolve and 1.3 g of ammoniumperchlorate were added to 410 g of the resultant three-elementhydrolysis solution to prepare a coating liquid for forming an overcoatlayer.

The above coating liquid (a) for forming an undercoat layer was appliedto a preliminarily washed polycarbonate substrate, air-dried for 15minutes, and then dried under heat at 125° C. in a hot-air dryingfurnace for 15 minutes. The dried undercoat layer had a thickness of 0.8μm. Thereafter, the coating liquid (b) for forming an overcoat layer wasapplied onto the undercoat layer on the polycarbonate substrate,air-dried for 15 minutes and then dried under heat at 125° C. in ahot-air drying furnace for 60 minutes. The dried overcoat layer had athickness of 4.3 μm.

The resultant coated polycarbonate article was transparent, and showedan abrasion resistance of A, an adhesion of 100/100 and excellent waterresistance. After it was subjected to a sunshine weatherometer test over3,000 hours, it had an excellent appearance, an excellent hardness andexcellent adhesion properties.

Comparative Example 1

Preparation of coating liquids for forming an undercoat layer:Copolymers having a composition shown in Table 1 was prepared in thesame manner as in Example 1. 100 Grams of propylene glycol monomethylether was added to 100 g of each of the copolymers to prepare coatingliquids for forming an undercoat layer. As a coating liquid (b) forforming an overcoat layer, the same coating liquid as that used inExample 1 was used.

The coating liquids for forming an undercoat layer were separatelyapplied to preliminarily washed polycarbonate substrates, air-dried for15 minutes and dried under heat at 125° C. in a hot-air drying furnacefor 15 minutes in the same manner as in Example 1. All of the driedundercoat layers had a thickness of 3.7 μm. Then, the above coatingliquid for forming an overcoat layer was applied onto each of theundercoat layers, air-dried for 15 minutes and dried under heat at 125°C. in a hot-air drying furnace for 60 minutes. All of the resultantovercoat layers had a thickness of 3.8 μm.

The above-obtained coated polycarbonate articles were defective inadhesion properties and water resistance as shown in Table 2.

                  TABLE 1                                                         ______________________________________                                                              Weight                                                  Sample                                                                              Composition     ratio                                                   ______________________________________                                        A     MMA/APMS/HMPBP  67/3/30  (The content of 2nd                                                           component was                                                                 smaller)                                       B     MMA/HMPBP       80/20    (No 2nd component                                                             was contained)                                 C     MMA/APMS/HMPBP  10/10/80 (The content of 3rd                                                           component was too                                                             large)                                         ______________________________________                                         MMA: methyl methacrylate                                                      APMS: acryloxypropyltrimethoxysilane                                          HMPBP: 2hydroxy-4-(2-hydroxy-3-methacryloxy)propoxybenzophenone          

                  TABLE 2                                                         ______________________________________                                                Adhesion     Water                                                    Sample  properties   resistance                                               ______________________________________                                        A       20/100       defective adhesion                                                                         0/100                                       B       0/100        defective adhesion                                                                         0/100                                       C       0/100        defective adhesion                                                                         0/100                                       ______________________________________                                    

Adhesion test in water resistance is the same as adhesion test inExample 1.

Comparative Example 2

(a) Preparation of a coating liquid for forming an undercoat layer: 62Grams of methyl methacrylate, 27 g of γ-acryloxypropyltrimethoxysilaneand 0.4 g of azobisisobutyronitrile were dissolved in 160 g of ethyleneglycol monoethyl ether, and under nitrogen atmosphere, the resultantmixture was stirred under heat at 90° C. for 4 hours to copolymerize theabove components.

The resultant copolymerization product had a solid content of 30% and aviscosity of 850 cps. 328 Grams of ethylene glycol monoethyl ether and7.5 g of 2,4-dihydroxybenzophenone (ultraviolet light absorber) wereadded to 100 g of the copolymer to prepare a coating liquid for formingan undercoat layer. As a coating liquid (b) for forming an overcoatlayer, the same coating liquid as that used in Example 2 was used.

The above coating liquid (a) for forming an undercoat layer was appliedto a preliminarily washed polycarbonate substrate, air-dried for 15minutes, and then dried under heat at 125° C. in a hot-air dryingfurnace for 20 minutes. The dried undercoat layer had a thickness of 1.0μm. Then, the above coating liquid (b) for forming an overcoat layer wasapplied onto the undercoat layer, air-dried for 15 minutes and driedunder heat at 125° C. for 60 minutes. The dried overcoat layer had athickness of 4.3 μm.

The resultant coated polycarbonate article was transparent and showed anabrasion resistance of A, an adhesion of 100/100 and good hot waterresistance. However, when the coated polycarbonate article was subjectedto a sunshine weatherometer test, it turned yellow extraordinarily after2,000 to 2,500 hours, and cracks were partly observed.

Further, when about 100 polycarbonate plates coated with the sameundercoat layer as above were immersed in the same coating liquid forforming an overcoat as that used above, the ultraviolet light absorberwas eluted into the coating liquid. As a result, the resultant coatedpolycarbonate articles showed an abrasion resistance of B to C, and adecrease in the adhesion properties was also observed. It has been foundthat a decrease in the adhesion properties tends to occur when more than2,500 ppm of the ultraviolet light absorber was eluted into the coatingliquid for forming an overcoat layer.

Example 3

(a) Preparation of a coating liquid for forming an undercoat layer: 8.5Grams of distilled water, 0.6 g of ammonium perchlorate and 400 g ofpropylene glycol monomethyl ether were added to 100 g of the samecopolymer as that prepared in Example 1, and the resultant mixture wasfully stirred to prepare a coating liquid for forming an undercoatlayer.

(b) Preparation of a coating liquid for forming an overcoat layer: 207Grams of methyltrimethoxysilane and 7.0 g of acetic acid were added to amixture consisting of 54 g of colloidal silica and 14 g of a colloidalantimony oxide, and the resultant mixture was stirred for hydrolysiswhile the temperature of the mixture was maintained at 50° C.Thereafter, 195 g of n-butanol, 195 g of isopropyl alcohol, 1.26 g ofsodium acetate and 11.0 g of acetic acid were added to the resultanthydrolysis product to prepare a coating liquid for forming an overcoatlayer.

The above coating liquid (a) for forming an undercoat layer was appliedto a preliminarily washed polycarbonate substrate, air-dried for 15minutes, and dried under heat at 125° C. in a hot air drying furnace for20 minutes. The dried undercoat layer had a thickness of 0.7 μm. Then,the above coating liquid (b) for forming an overcoat layer was appliedonto the undercoat layer, air-dried for 15 minutes, and dried under heatat 125° C. in a hot-air drying furnace for 60 minutes. The driedovercoat layer had a thickness of 3.8 μm.

The resultant coated polycarbonate article was transparent, and showedan abrasion resistance of A, an adhesion of 100/100 and excellent waterresistance. Further, after the coated polycarbonate article wassubjected to a sunshine weatherometer lest over 3,000 hours, it wasexcellent in appearance, hardness and adhesion properties.

Example 4

(a) Preparation of a coating liquid for forming an undercoat layer:Components (i), (ii) and (iii) were used in such a compositional ratiothat the content of the component (i) was 60% by weight, that of thecomponent (ii) was 15% by weight and that of the component (iii),benzophenone, was 25% by weight. That is, 96.9 g of methyl acrylate[component (i)], 24.2 g of γ-methacryloxypropyldimethylethoxysilane[component (ii)], 40.3 g of2-hydroxy-4-(2-hydroxy-3-methacryloxy)-propoxy-5-sulfonic benzophenone[component (iii)] and 0.7 g of azobisisobutyronitrile were dissolved in300 g of propylene glycol monomethyl ether, and under nitrogenatmosphere, the resultant mixture was stirred under heat at 80° C. for 5hours to copolymerize the components.

The resultant copolymerization product had a solid content of 35% and aviscosity of 750 cps. 80 Grams of propylene glycol monomethyl ether wasadded to 100 g of the copolymer to prepare a coating liquid for formingan undercoat layer.

(b) Preparation of a coating liquid for forming an overcoat layer: 0.2Gram of acetic acid was added to 68 g of colloidal silica in solid(aqueous dispersion having a solid content of 34%), and the mixture wasstirred. Then, 138 g of methytrimethoxysilane was added, and theresultant mixture was stirred for 2 hours for hydrolysis while thetemperature of the mixture was maintained at 40° C. Thereafter, 145 g ofn-butanol, 145 g of isopropyl alcohol, 1.2 g of sodium acetate and 10 gof acetic acid were added to the hydrolysis product to prepare a coatingliquid for forming an overcoat layer.

The coating liquid (a) for forming an undercoat was applied to apreliminarily washed copolymer containing methyl methacrylate andN-methyl-dimethyl-glutarimide units (Pohm & Haas: KAMAX), air-dried for15 minutes and dried under heat at 100° C. in a hot-air drying furnacefor 1 hour. The dried undercoat had a thickness of 3.8 μm. Then, theabove coating liquid (b) for forming an overcoat layer was applied ontothe undercoat layer, air-dried for 15 minutes, and dried under heat at120° C. in a hot-air drying furnace for 2 hours. The dried overcoatlayer had a thickness of 4.0 μm.

The resultant coated above mentioned copolymer article was transparent,and showed an abrasion resistance of A, an adhesion of 100/100 andexcellent water resistance. Further, after the coated above mentionedcopolymer article was subjected to a sunshine weatherometer test over3,500 hours, it was excellent in appearance, hardness and adhesionproperties.

The foregoing description of preferred embodiments of the invention hasbeen presented for purposes of description. It is not intended to beexhaustive or to limit the invention to the precise form disclosed, andmodifications and variations are possible in light of the aboveteachings or may be acquired from practice of the invention. Theembodiments were chosen and described in order to explain the principlesof the invention and its practical application to enable one skilled inthe art to utilize the invention in various embodiments and with variousmodifications as are suited to the particular use contemplate. It isintended the scope of the invention be defined by the claims appendedhereto, and their equivalents.

According to the present invention, the surface of a substrate is coatedwith an undercoat layer of an acrylic polymer having ultraviolet lightabsorbability. Therefore, the substrate is free from problems of elutionand migration caused by water, heat, etc. Further, the prevention ofphoto-oxidative deterioration can be maintained when the substrate isused for a long period of time.

According to the present invention, the polymer having ultraviolet lightabsorbability is not eluted into a coating liquid for forming anovercoat layer since it is in the state of polymer. Therefore, theovercoating properties at an initial time can be maintained for a longperiod of time, and such an adverse effect as the decreasing of the potlife of a coating liquid for forming an overcoat layer can be prevented.

Further, the coating liquid for forming an undercoat layer, provided bythe present invention, and a coating liquid for forming an overcoatlayer, used in the present invention, can give coated molded articleshaving high abrasion resistance.

What is claimed is:
 1. A resin molded article coated with an undercoatlayer of a coating composition, which contains a copolymer obtained fromthe following monomer compounds (i), (ii), and (iii),(i) an acrylic ormethacrylic compound containing at least one of the compounds of theformulae (I) and (II), ##STR6## wherein R¹ is hydrogen or a methyl groupand R² is an alkyl group, ##STR7## wherein R¹ is hydrogen or a methylgroup, R³ is an alkylene group, and X is a hydroxyl group, a carboxylgroup, an amine group, an epoxy group, an amido group or Si(OR⁴)₃ inwhich R⁴ is an alkyl group, (ii) an alkoxysilyl group-containing acrylicor methacrylic compound of the formula (III), ##STR8## wherein R¹ ishydrogen or a methyl group, R⁵ is a hydrocarbon group having 1 to 6carbon atoms, R⁶ is a hydrocarbon group having 1 to 5 carbon atoms, analkoxyalkyl group or an acyl group having 1 to 4 carbon atoms, and d is0, 1, or 2, and (iii) an acrylic or methacrylic compound havingultraviolet light absorbability selected from the group consisting of abenzophenone-substituted acrylic monomer of the formula (IV) ##STR9##wherein R¹ is hydrogen or a methyl group, R⁷ is an alkylene group(CH₂)_(n) in which n is 1 to 5 or a hydroxyalkylene group, Z ishydrogen, a hydroxyl group or a carboxyl group, X is hydrogen or analkoxy group OR⁸ in which R⁸ is an alkyl group of C_(n) H_(2n+1) inwhich n is 1 to 20, and Y is hydrogen, chlorine or a sulfonic acidgroup, and a triazole-substituted acrylic monomer of the formula (V),##STR10## wherein R¹ is hydrogen or a methyl group, R⁷ is an alkylenegroup --(CH₂)_(n) in which n is 1 to 5 or a hydroxyalkylene group, R⁸ isan alkyl group C_(n) H_(2n+1) in which n is 1 to 20 and X is hydrogen orchlorine and with an overcoat layer of an organopolysiloxane-containingcoating composition for forming an overcoat layer.
 2. The resin moldedarticle of claim 1, wherein monomer compound (i) comprises methylacrylate.
 3. The resin molded article of claim 1, wherein monomercompound (i) comprises methyl methacrylate.